Refractory sales and installation services | 905-730-4169

Refractory sales and installation services
905-730-4169

Salt River Materials Group, AZ

Cement Kiln Burner Pipe

BURNER PIPE DETAILS

Burner Pipe: Burner pipe is 26 feet long and approximately 30 inches in diameter.

Lining ConfigurationThe current ling consists of 1/4” layer of ceramic fiber blanket, with 3” of RESCO’s R-Max CZ high performance castable.

Customer Need: A solution was recommended to address the customers main challenge:

  • Continual refractory maintenance and repair due to thermal shock from cycling the kiln. On average, current refractory life is approximately 4 months.

RECOMMENDATION

Engineered Approach: A hot face coating was recommended to address the customers’ requirements. The coating design included a proprietary high emissivity hot face coating, ITC 100HT, applied to the hot face of the R-Max CZ.

High Temperature Energy Efficient Ceramic CoatingsITC manufactures several proprietary, high emissivity coatings to work in concert with refractory or metal substrates. Under ideal conditions, high emissivity coatings absorb energy from the process and re-radiate it to the load, imparting the following benefits:

  • Lower Maintenance costs – Protects the substrate refractory from thermal shock due to cyclical operation.
  • Lower Heat Loss – Minimizes heat transfer through the refractory and reduces oxidation of the burner pipe and premature failure of burner internal parts.

IMPACT ON THE PROCESS

Refractory Longevity – Current refractory maintenance costs are estimated at $35,000.00 to $50,000.00 per year. With the use of ITC Coatings refractory life is extended on average 2 to 3 times longer

IMPACT ON BOTTOM LINE COSTS

BTU Savings Per Year
Before: Complete burner reline, 3 times per year at a total yearly cost $50,000.00
After: Coating applied to hot face of burner refractory once per year at a total cost of $16,262.00

ROI = 3.1 months

TOTAL IMPACT/YEAR = $33,374